Alemite 8540-B User manual

SERVICE GUIDE 8540-B
8549-B1
8549-C
DESCRIPTION
The major components of the high-pressure pump models in this
series consist of a(n):
• air-operated motor
• lubricant pressure controller (pressurtrol)
• double-acting reciprocating pump tube.
The pressurtrol minimizes material pressure drop that occurs when
the pump cycles. Refer to SER 319800-1.
Pump Assembly
These high-pressure (70:1 ratio) pumps are designed to deliver a
range of greases [up to NLGT # 3] and operate directly from their
original container.
Models 8540-B, 8549-B1, and 8549-C
Pump model 8540-B is designed with a pump tube length to ac-
commodate 120-pound (50 kg) containers.
The 8549 series pumps are for 400-pound (180 kg) containers with
model 8549-B1 including a bung adapter. See Figure 1.
Specifications
Air Motor
Figure 1 Pump Models 8540-B and 8549 Series
Model 8549-B1 Shown
Alemite , LLC
167 Roweland Drive, Johnson City, Tennessee 37601
www .alemite.com
670763
SER 8540-B
Revision (12-14)
High-Pressure Lubricant Pump
Piston Diameter x Stroke Air Inlet
Max. Air Pressure *
Inches Centimeters psi Bars
3 x 1-5/8 76.2 x 41.3 1/4″NPTF (f) 200 13.8
* With pressurtrol, [100 psi (6.9 Bars) without pressurtrol] For information
on the air motor, refer to SER 324400-5
Pump tube
Material Outlet Max. Material Pressure Max. Delivery/ Minute
(Approximate)*
Displacement per
Cycle
psi Bars Ounces Grams in 3cm3
3/8″NPTF (f) 7500 517 32 909 0.277 4.54
* For detailed information, refer to Figure 4
Pump
Model
Container Size Bung
Adapter
X (X1) y
lbs kgs Inches Cm Inches Cm
8540-B 120 50 27-3/4 70.5 38-1/8 96.8
8549-B1 ●37 (35) 94 (89)
47-3/8 120.3
8549-C 400 180 37 94

SER 8540-B High Pressure Lubricant Pump
Figure 2 High-Pressure Lubricant Pump Models 8540-B and 8549 Series- Exploded View
2

SER 8540-BHigh Pressure Lubricant Pump
Repair Kits
Item
No.
Part No. Description Qty Notes
Numeric Order
Part # Item #
1 170292 Screw, Machine 8-32 x 1-1/4″ Long 1 43748 6
2 321085 Mufer 1 51017 14
3Motor Assembly, Air 1 See SER 324400-5 131168 38
4 327033 Adapter, 1/4″ NPTF (m) 1 170292 1
5 319800-1 Pressurtrol 1 See SER 319800-1 171000-20 42
6 43748 Body, Angle, 1/4″NPTF (m) and (f) 1 171013-12 12
7 328034 Connector, Air, 1/4″NPTF (m) 1 171033-5 17
8 328030 Coupler, Air, 1/4″NPTF (f) 1 171700-12 23
9 338507 Fitting, 90 °, 3/16″Tube x 1/8″NPTF (m) 2 l72l90-9 29
10 324971 Adapter, 3/8″PTF (f) x 3/8″NPTF (m) 1 l72l90-l0 34
11 324443 Tube, 3/16″OD 1 317536 24
12 171013-12 O-Ring, 1-1/8″TD x 1-1/4″ OD 1 ●Δ 317549 33
13 324805 Adapter 1 319800-1 5
14 51017 Gasket (Aluminum) 4 ●Δ 320704-1 18
15 320974 Coupling 1 320704-3 18
16 320971 Pin, 0.088″Dia. x 41/64″ Long 1 ●Δ 320705 19
17 171033-5 Pin, 1/8″ Dia. x .625″ Long 2 ●Δ 320712 40
18 320704-1 Rod, 17.75″ Long 1 Model 8540-B 320713 39
320704-3 Rod, 27.06″ Long 1 Model 8549-B1, -C 320716 36
19 320705 Coupling 1 320718 20
20 320718 Stop, Ball 1 320719 22
21 321605 Washer 1 328030 8
22 320719 Spring, 0.75″ Long 1 ●Δ 328034 7
23 171700-12 Ball, 3/16″ Dia. 1 ●Δ 320971 16
24 317536 Washer, Locking 1 ●Δ 320974 15
25 330332 Piston 1 Δ321085 2
337392 Tube, 21.25″ Long 1 Model 8540-B 321605 21
26 337392-2 Tube, 30.42″ Long 1 Model 8549-B1, -C 324400-5 3
27 Bearing (Brass) 1 ●Δ 324437 43
28 337391 Retainer 1 Δ324438-1 41
29 Seal, 0.540″ ID x 0.914″ OD 1 ●Δ 324438-2 41
30 Bearing (Brass) 1 ●Δ 324443 11
31 Gasket (Aluminum) 1.08″ ID 1 ●Δ 324805 13
32 337388 Extension 1 Δ324971 10
33 317549 Washer, Stop 1 ●Δ 326750 44
34 Seal, 0.282″ ID x 0.532″ OD 1 ●Δ 327033 4
35 337995 Body, Valve 1●Δ 330329 37
36 320716 Seat, Valve 1●Δ 330332 25
37 330329 Rod, 3.91″ Long 1 Δ330334 31
38 131168 Pin, 1/16″ Dia. x 0.50″Long 1 ●Δ 337388 32
39 320713 Disc, Primer 1 ●Δ 337389 30
40 320712 Nut, Elastic Stop, 12- 28 1 ●Δ 337391 28
41 324438-1 Tube, Follower, 25-9/16″Long 1 Model 8540-B 337392 26
324438-2 Tube, Follower, 34-11/16″ Long 1 Model 8549-B1, -C 337392-2 26
42 171000-20 O-Ring, 1-1/16″ TD x 1-5/16″OD 1 ●Δ 337393 27
43 324437 Body, Primer 1 337995 35
44 326750 Adapter, Bung, 2″ NPTF (m) 1 Model 8549-B1 338507 9
Legend:
Part numbers left blank (or in italics) are not available separately
●Δ designates a repair kit item
Part No. Kit
Symbol Description Notes
393514 ● Kit, Major Repair
393516 ΔKit, Conversion See Page 4
393530-9 Kit, Seal [includes ve (5) of item number 29]
393530-10 Kit, Seal [includes ve (5) of item number 34]
3

SER 8540-B High Pressure Lubricant Pump
Early Model Pumps
The earlier versions of these model pumps did not contain seals in
the tube assembly. The Piston and Lower Rod cycled in “select-fit”
bores. See Figure 3.
Any earlier model pump that has not been repaired since 1983 re-
quires a 393516 conversion kit.
Conversion Kit
NOTE: In addition to the contents within the kit, the existing pump
tube must be replaced. See Table 2 for the appropriate part number.
Install the Kit
To reassemble the pump with the conversion kit, follow the proce-
dures outlined in the section entitled Assembly.
1 Pump Model Pump Tube
Part No. Length
8540-B 337392 21.25″
8549 Series 337392-2 30.42″
Noise level test
Distance 60 psi (4,1 bar) 100 psi (6,8bar)
3 ft. (0,9 m)96 dB 98 dB
Figure 3 Early Model Pump Tubes- Section View
4

SER 8540-BHigh Pressure Lubricant Pump
Accessories
2 Model
Number
Container
Size Follower Cover Bung Adapter
8540-B 120 lbs 338802 338371 326750
50 kg 338993 338983
8549-B1 400 lbs 338911 318040-4 Included with
Model
180 kg 338994 338984
8549-C
400 lbs 338911 318040-4
326750
180 kg 338994 338984
Performance Chart
A pump’s ability to deliver material is based on the pressure (psi/Bars) and quantity (cfm/lpm) of air supplied to the motor and the amount of
material discharge [back] pressure to be overcome within the system.
This chart contains curves based on three different air pressures. The curves relate delivery in ounces (grams) per minute (X axis) to air con-
sumption in cubic feet (liters) per minute (right Y axis) and to material discharge pressure in psi/Bars (left Y axis).
Table 3 Pump Models 8540-B and 8549 Series Accessories
Figure 4 Delivery Versus Discharge Presure And Air Consumption
5

SER 8540-B High Pressure Lubricant Pump
6

SER 8540-BHigh Pressure Lubricant Pump
IMPORTANT:Prior to performing any maintenance procedure, the
following safety precautions must be observed. Personal in}ury
may occur.
WARNING
Do not use halogenated hydrocarbon solvents such
as methylene chloride or 1,1,1-trichloroethane in this pump. An
explosion can result within an enclosed device capable of con-
taining pressure when aluminum and/or zinc-plated parts in the
pump come in contact with halogenated hydrocarbon solvents.
Release all pressure within the system prior to performing any
overhaul procedure.
• Disconnect the air supply line from the pump motor.
• Into an appropriate container, operate the control valve to
discharge remaining pressure within the system.
Never point a control valve at any portion of your body or anoth-
er person. Accidental discharge of pressure and/or material can
result in injury.
Read each step of the instructions carefully. Make sure a prop-
er understanding is achieved before proceeding.
Overhaul
NOTE: Refer to Figure 2 for component identification on all
overhaul procedures.
Disassembly
1 Secure the pump assembly in a soft-jaw vise at Adapter (13).
NOTE: Secure model 8549-B1 at Bung Adapter (44).
2 Extend Rod (37) to end of Primer Body (43).
• Apply air to the motor as necessary.
3 Gently remove Nut (40) from the Rod.
• Use an appropriate size punch in the hole of the Rod to prevent
rotation. See Figure 2.
4 Remove Primer Disc (39) from the Rod.
5 Push the Rod into the Primer Body.
Pump Tube (Outer Components)
6 Rotate the Primer Body.
• Use a large wrench or other suitable tool.
NOTE: The pump tube will break at one of three places. Unscrew
the separated portion from the inner components of the pump tube
assembly.
7 Remove Follower Tube (41) [assembly] from the inner tube
assembly.
8 Unscrew the air motor from Adapter (13).
• Rotate the air motor assembly.
9 Remove O-Ring (12) from the Adapter.
NOTE: If the pump was not leaking at the top of Tube (26), do not
separate the Adapter from the Tube. Components are locked with
Loctite® 222 ™.
10 Unscrew Tube (26) from the Adapter as required.
• Remove Gasket (14).
11 Clamp Retainer (28) horizontally in a soft-jaw vise.
12 Unscrew the Primer Body from Extension (32).
13 Remove O-Ring (42) from the Primer Body.
IMPORTANT: Remove Valve Seat (36) squarely from the Primer
Body. Should the Valve Seat cock during removal, realign and
start again. Gasket (14) may interfere.
14 Remove Valve Seat (36) from the Primer Body.
15 Remove Gasket (14) from the Valve Seat.
16 Unscrew the Extension from the Retainer.
17 Remove Gasket (31) from the Extension.
18 Remove Valve Body (35) from the Extension.
•Remove Stop Washer (33).
19 Remove Seal (34) from the Valve Body.
20 Remove Bearing (30) and Seal (29) from the Retainer.
21 Unscrew Tube (26) from the Retainer.
22 Remove Gasket (14), Bearing (27), and additional Gasket (14)
from the Retainer.
7

SER 8540-B High Pressure Lubricant Pump
Pump Tube (Inner Components)
23 Remove Pin (16) that secures Coupling (15) to the air motor rod.
•Unscrew the Coupling assembly from the air motor rod.
24 Clamp Coupling (19) in a soft-jaw vise.
25 Remove upper Pin (17) that secures Coupling (15) to Rod (18).
• Unscrew the Rod from the Coupling.
26 Remove lower Pin (17) that secures Coupling (19) to the Rod.
• Unscrew the Rod from the Coupling.
27 Remove Pin (38) that secures Piston (25) to Rod (37).
• Unscrew the Rod from the Piston.
28 Straighten the tabs on Locking Washer (24).
29 Unscrew Piston (25) from the Coupling.
30 Remove the Locking Washer from the Piston.
31 Remove Ball (23) from the Piston.
32 Remove Spring (22) and Washer (21) from Ball Stop (20).
NOTE: Separate the Ball Stop from the Coupling only if the
connection is loose.
33 Unscrew the Ball Stop from the Coupling as needed.
Pressurtrol
34 Remove Air Coupler (8) from Air Connector (7).
35 Loosen both Fittings (9) that secure Tube (11).
36 Loosen Pressurtrol (5) from Adapter (4).
• Remove the Tube from the Fittings.
37 Unscrew the Pressurtrol from the Adapter.
• Remove the Adapter from Air Motor (3) as needed.
38 Unscrew the Fitting from the Pressurtrol as needed.
39 Unscrew Angle Body (6) from the Pressurtrol as needed.
40 Unscrew Air Connector (7) from the Angle Body as needed.
41 Unscrew the additional Fitting from Adapter (10) as needed.
42 Remove the Adapter from the Air Motor as needed.
Clean and Inspect
NOTE: Use the appropriate repair kit for replacement parts.
Make sure all the components are included in the kit and in good
condition before discarding used parts.
1 Clean all metal parts in cleaning solvent. The solvent should be
environmentally safe.
2 Inspect all parts for wear and/or damage.
• Replace as necessary.
3 Inspect Piston (25) closely. Use a magnifying glass to detect any
wire draw marks.
• Replace as necessary.
4 Closely inspect the mating surfaces of all components for any im-
perfections. Ensure a smooth and clean contact is obtained when
assembled.
EXAMPLE: Place Ball (23) into Piston (25). Fill the Piston with
solvent. Make sure no leakage occurs.
Assembly
NOTE: Prior to assembly, certain components require lubrication
in clean oil. Refer to Table 4 for details.
Pump Tube (Inner Components)
NOTE: Refer to Figure 5 for a section view of the pum p tube
assembly.
1 Place Ball (23) into Piston (25).
2 Screw and seat Ball Stop (20) [ Loctite®242®]. into Coupling (19).
• Follow the thread sealant manufacturer’s recommendations.
• Tighten securely.
3 Install Washer (21) and Spring (22) onto the Ball Stop.
Item No. on
Figure 2 Description
12 O-Ring, 1-1/8″TD x 1-1/4″OD
29 Seal, 0.540″TD x 0.914″OD
34 Seal, 0.282″TD x 0.532″OD
42 O-Ring, 1″ TD x 1-1/4″OD
4 Position Locking Washer (24) into the groove on the top of the
Piston.
5 Screw the Coupling assembly into the Piston.
• Tighten from 19 to 21 foot pounds (25.4 - 28.3 Nm)
• Continue to tighten and align the nearest flat of the Coupling
with the tabs on the Locking Washer.
IMPORTANT: Press on the Ball to ensure it moves a minimum of
1/8″(3.2 mm) prior to contact with the Ball Stop. Should the value
be less, check to ensure the Ball Stop is fully seated in the Coupling.
6 Bend the tabs of the Locking Washer upward onto the Coupling.
7 Screw Rod (37) into the Piston until the pin holes align.
NOTE: Use a spot of grease on all pins to prevent
movement.
8 Install Pin (38).
8

SER 8540-BHigh Pressure Lubricant Pump
Figure Pump Tubes 337384-Al, and Bl - Section View
9 Screw Rod (18) into Coupling (19) until
the pin holes align.
• Install Pin (17).
10 Screw Coupling (15) [end without coun-
ter-bore] onto the Rod until the pin holes
align.
• Install additional Pin (17).
11 Secure the air motor assembly in a soft-jaw
vise.
12 Screw the Coupling assembly onto the
air motor rod until the pin holes align.
• Install Pin (16).
Pump Tube (Outer Components)
13 Install and seat Seal (29) [lips first] into the
bottom of Retainer (28). See Figure 2.
14 Install and seat Bearing (30) into the bot-
tom of the Retainer.
15 Install Gasket (31) onto the top of Exten-
sion (32).
IMPORTANT: If a primer is used with
Loctite 222 , the curing time is greatly
reduced.
16 Screw the Extension [with Loctite 222]
(Gasket end first) into the bottom of the
Retainer.
• Follow the thread sealant manufactur-
er’s recommendations.
• Do not tighten at this.
17 Install Gasket ( 14 ) into the top of the
retainer.
18 Install and seat Bearing (27) [small diam-
eter first] and additional Gasket (14) into
the top of the Retainer.
19 Screw Tube (26) [with Loctite 222] into
the top of the Retainer.
• Do not tighten at this time.
20 Install and seat Gasket (14) into Adapter
(13).
21 Screw the Tube assembly [with Loctite
222] into the Adapter.
• Do not tighten at this time.
22 Install O-Ring (12) onto the Adapter.
23 Apply grease to Piston ( 25 )
• This will aid the installation
9

SER 8540-B High Pressure Lubricant Pump
CAUTION
Install the outer component assembly onto the inner assembly
with care. Damage to Seal (29) can occur.
24 Install the outer component assembly onto the inner assembly.
• Use a slight twisting motion to pass the Seal
•At the same time thread the Adapter into the base of the air
motor.
IMPORTANT: Make sure the flange portion of the Adapter seats
flush against the base of the air motor. Should a gap exist, inspect
the components of the air motor packing group.
25 Install Stop Washer (33) into the Extension.
26 Install and seat Seal (34) [heel end first] into Valve Body (35).
27 Install the Valve Body assembly (Seal first) onto Rod (37).
•Make sure the Valve Body assembly seats properly in the
Extension.
28 Install Follower Tube (41) over the outer tube assembly.
29 Install O-Ring (42) onto Primer Body (43).
30 Install and seat Valve Seat (36) [large diameter first] into the
Primer Body.
31 Install and seat Gasket (14) into the Primer Body.
32 Screw the Primer Body onto the Extension.
33 Place a large wrench or other suitable tool into the slot of the
Primer Body.
• Tighten all the components of the assembly securely.
• Crush all Gaskets.
34 Extend Rod (37) from the Primer Body.
• Apply air to the motor as necessary.
35 Install Primer Disc (39) onto the Rod.
36 Gently screw Nut (40) onto the Rod.
•Use an appropriate size punch in the hole of the Rod to prevent
rotation. See Figure 2.
• Do not overtighten.
Model Dependent Step
37 Install Bung Adapter (44) onto the Follower Tube.
model8549-Bl].
Pressurtrol
Screw Fitting (9) [with thread sealant] and Angle Body (6) [with
thread sealant] into the Pressurtrol.
• Tighten each component securely.
• Make sure to orient the components properly.
38 Screw Air Connector (7) [with thread sealant] into the Angle
Body.
• Tighten the Air Connector securely.
39 Screw Adapter (4) [with thread sealant] into Air Motor (3).
•Tighten the Adapter securely.
40 Screw Pressurtrol (5) onto the Adapter [with thread sealant].
IMPORTANT: Tighten the Pressurtrol just short of vertical. This
allows the assembly of Tube (11).
41 Screw Adapter (10) into the Air Motor.
• Tighten the Adapter securely.
• Make sure to orient the Adapter properly.
42 Screw additional Fitting (9) into the Adapter.
• Tighten the Fitting securely.
• Make sure to orient the Fitting properly.
43 Position Tube (11) into each Fitting.
44 Secure the Tube by rotating the Pressurtrol to vertical.
• Tighten the Fittings to the Tube.
45 Install Air Coupler (8) onto the Air Connector.
Operation
WARNING
Do not exceed the lowest pressure rating of any
component in the system.
Do not alter the design of the pump. Never install addition-
al components to the outlet of the pressurtrol.
Never point a control valve at any portion of your body or
another person. Lubricant discharged at high velocity can
penetrate the skin and cause severe injury. Should any flu-
id appear to puncture the skin, get medical care
immediately.
Ensure all components are in operable condition. Replace
any suspect parts prior to operation. Personal injury can
occur.
1 Make sure air pressure at the regulator reads zero.
2 Slowly supply air pressure [not to exceed 20 psi (1.4 Bars)] to the
pump’s motor.
• The pump assembly should cycle.
If the pump assembly does not cycle, refer to the Troubleshooting
Chart for details.
With air pressure at zero:
3 Connect a product hose to the pressurtrol’s material outlet.
• Direct the hose into an appropriate collection container.
4 Place the pump in grease.
5 Slowly supply air pressure to the pump’s motor.
6 Allow the pump to cycle slowly until the system and grease is free
of air.
If the pump assembly does not prime, refer to the Troubleshooting
Chart for details.
10

SER 8540-BHigh Pressure Lubricant Pump
WARNING
Should leakage occur anywhere within the system,
disconnect air to the motor. Personal injury can occur.
With air pressure at zero:
7 Attach a control valve to the outlet hose of the pump.
8 Set the air pressure to 100 psi (6.9 Bar).
9 Operate the control valve into a container.
10 Allow the pump to cycle until the system and grease is once again
free of air.
11 Shut off the control valve.
• Visually inspect the pump for external leaks.
• The pump should not cycle.
If the pump does not stall, refer to the Troubleshooting Chart for
details.
12 Check the motor for air leakage.
If the motor leaks, refer to the Air Motor Service Guide for details.
Installation
Part Number Description
338860 Moisture Separator/Regulator & Gauge Combination
5604-2 Moisture Separator
7604-B Regulator and Gauge
5904-2 Lubricator *
Table 5 Air Line Components
* Although the air motor is lubricated at the factory, the life of the
motor can be extended with the use of a lubricator.
Declaration of conformity as defined by
Machinery Directive 2006/42/EC
This is to declare that the design of the low pressure fluid lubricant
pump complies with the provisions of directive 2006/42/CG
Applied standards:
• EN 292-1 Safety of Machinery - Basic Concepts, General
Principles and Design - Part 1: Basic Terminology, Methodology
• EN 292-2 Safety of Machinery - Basic Concepts, General
Principles and Design - Part 2: Technical Principles and
Specifications - Incorporates amendments 1 (1995) and 2 (1997)
• EN 809 Pumps and Pump Units for Liquids - Common Safety
Requirements
• EN 349 Safety of Machinery - Minimum Gaps to Avoid Crushing
of Parts of the Human Body
St. Louis, MO 08/14,
Bob Hoefler, Director Product Development and Product Engineering
11

SER 8540-B High Pressure Lubricant Pump
Troubleshooting Chart
Changes Since Last Printing
Added CE compliance
Loctite, 222, and 242 are trademarks of Henkel Corporation in the U.S. and elsewhere. ® denotes a trademark registered in the U.S. Patent
Trademark office.
3 Pump Indications Possible Problems Solution
Pump does not cycle 1. Air motor not operating properly 1. Inspect air motor and rebuild or
replace as necessary
2. Pump tube jammed and/or contains
loose components 2. Rebuild pump tube
3. Insufcient air pressure 3. Increase air pressure
Pump will not prime 1. Excessive cycling speed 1. Reduce air pressure
2. Pump leaking internally 2. See Internal Leaks
Pump cycles rapidly Product source empty Replenish product
Pump cycles continuously, or slowly
(once or twice/hour)
1. Pump leaking internally 1. See Internal Leaks
2. Pump leaking externally 2. See External Leaks
3. Distribution system leaking 3. Correct leak
External Leaks
Product leakage visible at top of Adap-
ter (13)
1. Initial tightening of Adapter (13) to Air
Motor Assembly (3) not sufcient
1. Tighten Adapter (13) into Air Motor
Assembly (3)
2. Damaged O-Ring (12) 2. Replace O-Ring (12)
Product leakage visible at top of Fol-
lower Tube (41)
1. Initial tightening of Tube (26) to Adapter 1. Tighten Tube (26) into Adapter (13)
(13) not sufcient
2. Initial tightening of Tube (26) to Retai-
ner (28) not sufcient 2. Tighten Tube (26) into Retainer (28)
3. Initial tightening of Extension (32) to
Retainer (28) not sufcient
3. Tighten Extension (32) into Retainer
(28)
4. Initial tightening of Extension (32) to
Primer Body (43) not sufcient
4. Tighten Extension (32) into Primer
Body (43)
5. Gasket(s) (14) worn or improperly
crushed 5. Replace Gasket(s) (14)
6. Gasket (31) worn or improperly crushed 6. Replace Gasket (31)
Product leakage visible at bottom of
Follower Tube (41)Damaged O-Ring (42) Replace O-Ring (42)
Internal Leaks
Pump does not prime or cycles continu-
ously, or slowly (once or twice/hour)
1. Foreign material between Ball (23) and
seat in Piston (25)
1. Locate and eliminate source of foreign
material.
2. Foreign material between Valve Body
(35) and Valve Seat (36)
2. Disassemble pump tube, clean,
inspect, and replace worn or damaged
components.
3. Worn or damaged Ball (23)
4. Worn or damaged Piston (25)
5. Worn or damaged Spring (22)
7. Worn or damaged Valve Body (35)
8. Worn or damaged Valve Seat (36)
9. Worn or damaged Seal (29)
10. Worn or damaged Seal (34)
11. Worn or damaged Rod (37)
12